Articles and methods for applying color on surfaces

ABSTRACT

Articles for applying color on a surface comprise a sheet of dry color component and an adhesive on one surface of the sheet of dry color component. The article further includes a releasable liner, and the sheet of dry color component is arranged between the releasable liner and the adhesive. Methods for providing a substantially permanent color effect on an architectural surface comprise delivering such an article to the architectural surface.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.10/324,559, filed Dec. 13, 2002, now pending, which claims the benefitof U.S. Provisional Application No. 60/343,146, filed Dec. 20, 2001;U.S. Provisional Application No. 60/380,225, filed May 13, 2002; andU.S. Provisional Application No. 60/380,205, filed May 13, 2002.

FIELD OF THE INVENTION

The present invention is directed to articles and methods for applyingcolor on a surface, for example an architectural surface, wherein a drycolor component is employed and the use of wet tools such as brushes,sprayers and rollers, mess protection, color component cleaningmaterials and liquid volatile organic components for the colorcomponents may be avoided.

BACKGROUND OF THE INVENTION

It is often desirable to apply one or more colors to a surface, forexample an architectural surface such as an interior or exterior wall orthe like, for aesthetic benefits and/or functional benefits such aswater resistance. Color is typically provided by conventional paintingwith water-based or oil-based wet paints, application of wallpaper orthe like. The laborious processes involved with wet painting and wallpapering are well known. Typically, it is necessary to protectsurrounding areas from collateral mess during such activities by tapingadjacent surfaces where the color is not desired, arranging drop clothesto protect floors and furniture, and the like. Extreme care must also beexercised to avoid dripping of paint, wallpaper paste or primer, orother wet-applied materials. Many wet paint and wall paper products arealso recommended for use together with one or more primers or bases toassist in coverage and/or durability of the desired color, therebyincreasing the time and labor for producing a desired color effect onsuch a surface. Additionally, it is typically necessary to saturatebrushes, rollers or other applicators with paint, primer, paste or thelike in order to apply the material to a surface. As a result, asignificant amount of material is wasted, as it never reaches theintended surface, but remains on the applicator. Cleaning of brushes,sprayers, rollers and other tools used in application of wet paint andwall paper once painting or wall papering is completed, or at leastsuspended for a period of time, such as overnight, is also timeconsuming.

Many paints adapted for application to surfaces such as architecturalsurfaces include one or more volatile organic compounds. Such paintsrelease noxious fumes during and after application, thereby requiringventilation during and after application, particularly in closedenvironments such as buildings.

Thus, in spite of the obvious aesthetic and/or functional benefitsprovided by applying color on a surface by wet painting or wallpapering, the efforts required in connection with such procedures areinconvenient and time consuming.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the invention to provide articles andmethods for applying color on a surface, for example an architecturalsurface, which overcome various disadvantages commonly associated withconventional wet painting and/or wall papering procedures.

In one aspect, the invention is directed to articles for applying coloron a surface. In a first embodiment, the invention is directed to anarticle for applying color on a surface, which article comprises a sheetof dry architectural surface color component, an adhesive on one surfaceof the sheet of dry color component, and a releasable liner, wherein thesheet of dry color component is arranged between the releasable linerand the adhesive, wherein the adhesive is adapted to adhere the articleto a surface at room temperature and upon application of a pressure ofless than about 50 lb/in², and wherein the article exhibits anelongation of less than 50%.

In another embodiment, the invention is directed to an article forapplying color on a surface, which article comprises a sheet of drycolor component, an adhesive on one surface of the sheet of dry colorcomponent, and a releasable liner, wherein the sheet of dry colorcomponent is arranged between the releasable liner and the adhesive, andwherein the adhesive is adapted to exhibit an initial tack in responseto a first condition and a subsequent tack greater than the initial tackin response to a second condition. The subsequent tack is adapted toprovide a substantially permanent bond of the sheet of dry colorcomponent to a surface.

In a further embodiment, the invention is directed to articles forapplying color on a surface, comprising a sheet of dry color componentand an adhesive on one surface of the sheet of dry color component. Thesheet of dry color component and the adhesive are adapted to provide asurface covering having a water vapor transmission rate of at least 1g/μm/cm²/24 hrs.

In yet a further embodiment, the invention is directed to articles forapplying color on a surface, comprising a sheet of dry color componentand an adhesive on one surface of the sheet of dry color component. Thesheet of dry color component exhibits a specular reflectance of lessthan about 60 glass units at 60°.

In another aspect, the invention is directed to methods for providing asubstantially permanent color effect on an architectural surface. In oneembodiment, the methods comprise delivering an article according to oneof the embodiments described above to the architectural surface.

The articles and methods of the invention are advantageous in that colormay be applied on a surface without requiring the use of wet tools suchas brushes, sprayers and rollers for delivery of the articles orapplication of the dry color component, mess protection, or colorcomponent cleaning materials, and the dry color component issubstantially free of volatile organic components. The articles andmethods are further advantageous in that color may be applied on asurface in a less time-consuming manner as compared with typical wetpainting and/or wall papering products and methods. These and additionalobjects and advantages will be more fully apparent in view of thefollowing detailed description.

BRIEF DESCRIPTION OF THE DRAWING

The following detailed description will be more fully understood in viewof the drawings in which:

FIG. 1 sets forth a schematic diagram of one embodiment of an articlefor applying color on a surface according to the present invention;

FIG. 1A sets forth a schematic diagram of an article as set forth inFIG. 1, including a reinforcing component;

FIG. 1B sets forth a schematic diagram of an article as set forth inFIG. 1, wherein the sheet of dry color component includes an additionalprotective film layer;

FIG. 2 sets forth a schematic diagram of another embodiment of anarticle for applying color on a surface according to the presentinvention;

FIG. 2A sets forth a schematic diagram of another embodiment of anarticle for applying color on a surface according to the presentinvention;

FIG. 3 sets forth a schematic diagram of another embodiment of anarticle for applying color on a surface according to the presentinvention; and

FIG. 4 sets forth a schematic diagram of one process for producing anarticle for applying color on a surface according to the presentinvention.

The embodiments set forth in the drawing are illustrative in nature andare not intended to be limiting of the invention defined by the claims.Moreover, individual features of the drawing and the invention will bemore fully apparent and understood in view of the detailed description.

DETAILED DESCRIPTION

The present invention is directed to articles and methods for applyingcolor on a surface. As employed herein, the term “color” is used torefer to a color effect, i.e., a difference in color perception. In aspecific embodiment, the color effect is a substantially permanent coloreffect, i.e., a color effect which is not removed or noticeably reducedupon casual contact, light washing, or the like. Thus, a substantiallypermanent color effect is distinguished from a temporary color effectwhich can be easily removed or reduced, such as that provided by chalkor crayons. The term “color component” is used herein to refer to thecomponent of the inventive articles which provides the color effect.Exemplary color components will be described in further detail below.

The term “surface” is used herein to refer to any outer layer orboundary of an object or substrate which is capable of receiving a colorcomponent thereon. Suitable surfaces may be substantiallytwo-dimensional and flat or substantially three-dimensional andincluding curves, angled portions or the like. In one embodiment, thesurface to which color component is applied using the articles andmethods of the invention comprises an architectural surface, i.e., asurface of a building, a building fixture (i.e., appliances), furniture,and the like. The architectural building surface may be an interiorsurface within the building or an exterior surface on an outer portionof the building. Substantially three-dimensional architectural surfacescan include, for example, edge treatments of two-dimensional surfacessuch as moldings (e.g., moldings around windows or doorways),floorboards, appliances, furniture, and the like. The architecturalsurface may be permanently installed or may be temporarily installed orportable. The products of the present invention can further be appliedto surfaces of articles to give them the same or different textureand/or appearance of architectural surfaces. For example, the productshereof can be used to apply a color layer to appliances, furniture, andother architectural articles. Additional surfaces suitable forapplication of color using the articles and methods of the presentinvention will be apparent to those skilled in the art in view of thepresent disclosure.

The term “wet” is used herein to refer to an article or process stepwhich employs a liquid carrier. On the other hand, the term “dry” isused herein to refer to an article or process step substantially free ofa liquid carrier such that immobilization of a color component isaffected, i.e., the color component does not flow or move along thesurface under ambient conditions. Thus, a dry color component issubstantially free of a liquid carrier or vehicle, whereby the colorcomponent is physically immobilized in the article in which it isincluded. Similarly, reference herein to delivery of a dry colorcomponent without the use of liquid vehicles or carriers refers to thedry color component substantially free of liquid vehicle or carrier suchthat the color component is physically immobilized in the article inwhich it is included.

Thus, the dry color component employed in the articles of the presentinvention is substantially free of volatile organic components (VOC's)and water. According to standards of the Environmental ProtectionAgency, architectural coatings containing less than 250 g/l of volatileorganic components are substantially free of such components. Inselected embodiments of the present invention, the dry color componentcontains less than 250 g/l, more specifically about 200 g/l or less,more specifically about 100 g/l or less, and even more specificallyabout 50 g/l or less of volatile organic components. In furtherembodiments, the dry color component contains about 25 g/l or lessvolatile organic components, and more specifically about 20 g/l or lessvolatile organic components. In further embodiments, the dry colorcomponent similarly contains less than 250 g/l, more specifically about200 g/l or less, and even more specifically about 100 g/l or less ofwater. In more specific embodiments, the dry color component containsabout 50 g/l or less of water, and more specifically, about 25 g/l orless, more specifically about 20 g/l or less of water.

As will be discussed in further detail below, the articles and methodsfor applying color on a surface according to the present inventionexhibit a number of advantageous properties. For example, the articlesand methods of the invention are adapted for color application at roomtemperature and at relatively low application pressures, whereby thearticles may be applied by ordinary consumers without the use ofexcessive pressure. Additionally, various surface effects can beprovided.

The articles and methods may be employed to provide a porous surfacecovering which allows air to escape as the article is applied to asurface, thereby avoiding bubbles and/or wrinkles from appearing on acovered surface. In certain embodiments, the surface covering which isprovided is microporous and therefore allows moisture to escape ratherthan accumulating between the applied article and a surface to which itis applied. For example, the surface coverings provided by the articlesand methods according to the present invention may exhibit a water vaportransmission rate (WVTR) of greater than about 1 g-μm/cm²/24 hrs, morespecifically, greater than about 4 g-μm/cm²/24 hrs, at 100% relativehumidity and 40° C. as measured according to ASTM F1249-90. The desiredWVTR may be provided through the use of materials which inherently allowwater vapor transmission and/or by providing pores, perforations,orifices or the like in the articles, either on a micro or macro scale.These and additional advantageous properties provided by the articlesand methods of the invention will be further described hereafter.

FIG. 1 sets forth a schematic diagram of one embodiment of the articlesaccording to the present invention. With reference to FIG. 1, thearticle 10 for applying color on a surface comprises a sheet 12 of drycolor component and an adhesive 14 on one surface 16 of the sheet 12 ofdry color component. The sheet 12 is shown as a single layer of drycolor component. While the schematic diagram of FIG. 1 shows relativethicknesses of the sheet 12 and the adhesive 14, the illustratedthicknesses provide no representation or limitation of actualthicknesses of the respective components in the embodiment of FIG. 1 orin any of the embodiments of the remaining Figures. Additionally, whilethe interface between the components is shown as a clearly defined line,the actual interface between components may comprise other, differentconfigurations.

As employed herein, the term “sheet of dry color component” is intendedto refer to those portions of the inventive article which contribute tothe color effect rendered to a surface, but does not include areleasable liner or other portions of the article which are not adaptedfor adherence, preferably substantially permanent adherence as describedhereafter, to a surface to render the color effect. Thus, as will bedescribed in further detail below, the sheet of dry color component mayinclude not only a dry color component layer as shown in FIG. 1 but, inaddition, one or more topcoat layers and/or one or more backing layerswhich contribute to the color effect.

Typically, the sheet of dry color component will have a thickness ofless than about 0.003 inch (3 mils or 0.08 mm). In one embodiment, thesheet of dry color component will have a thickness of from about 0.0003inch (0.3 mils) to about 0.003 inch (about 0.008 mm to about 0.08 mm),more specifically from about 0.0003 inch to about 0.0015 inch (about0.008 mm to about 0.04 mm). In another embodiment, the sheet of drycolor component will have a thickness about 0.0007 inch (0.02 mm) orless, and even more specifically not more than about 0.0005 inch (0.013mm).

In embodiments wherein the article comprises the sheet of dry colorcomponent and adhesive, in the absence of layers such as liners orcarriers, the thickness of the articles will be essentially that of thesheet of dry color component, as the adhesive layer is typicallyrelatively thin, i.e., generally less than about 1 mil (0.001 inch or0.03 mm) in thickness, more specifically about 0.5 mil (0.0005 inch or0.013 mm) in thickness. Thus, in one embodiment, the sheet of dry colorcomponent and adhesive combined have a thickness of about 0.003 inch (3mils or 0.08 mm) or less, more specifically from about 0.0003 inch toabout 0.003 inch (about 0.008 mm to about 0.08 mm), even morespecifically from about 0.0003 to about 0.0015 inch (about 0.008 mm toabout 0.04 mm), and yet more specifically about 0.0007 inch (0.013 mm)or less. Advantageously, edges of adjacent sheets may thus be overlappedwithout significant overlap appearance. In further embodiments whereinone or more releasable liners are included, the thickness of thearticles will be increased.

The dry color component is provided in at least one layer in the sheetof dry color component and may comprise any composition which providesopacity coverage to a surface to which it is applied. The dry colorcomponent may comprise, for example, pigment or dye, as well ascombinations thereof; and a binder. Stains, inks, and paints areexamples of compositions that may contain pigment and/or dye incombination with binder. Examples of dry color components include inks,stains, paints, and coatings similar to “wet” compositions, except fortheir being characterized by having low levels of solvent, liquidcarrier, and other liquids as hereinbefore described. The binder can bea polymeric material that forms a coating, sheet, or film. A widevariety of binder materials are well known in the art and can be used inthe present invention. Suitable binder materials are disclosed, forexample, in the Enlow et al U.S. Pat. No. 6,336,988. Suitable bindermaterials can include the same polymeric materials described below foruse as topcoats. Examples of binder materials also include polystyreneand polyacrylate/polyvinyl chloride blends. The sheet of dry colorcomponent can constitute a dry color component coating layer applied toanother layer that is intended to remain on the surface to be colored,as described herein, or, alternatively, the sheet of dry color componentmay constitute a dry color component layer with sufficient integritysuch that another layer is not required therein for substantiallypermanent application to the surface to be colored.

In one embodiment, the dry color component comprises a combination of(i) dry pigment and/or dye and (ii) binder, alone or in combination withadditional components. For example, in specific embodiments, the drycolor component comprises dry paint, which includes pigment incombination with additional conventional paint components, for examplebinder, from which a liquid carrier is removed, dry ink, which typicallyincludes fine pigment or dyes, alone or in combination with additionalconventional ink components, including opacifying agents, from which aliquid carrier is removed, dry stain, dry ink, or a combination of twoor more of these components. The sheet of dry color component maycomprise a single, solid homogenous color with a smooth finish or with atextured finish or may comprise regular or irregular patterns of two ormore color components, and/or layers of color components. The sheet ofdry color component may have a flat, eggshell, satin, semi-gloss, orgloss finish, as desired. The particular finish may be controlled byselection of color components and/or by selection of a releasable linerof suitable finish, if employed. Texture may be added either within thelayer of dry color component, through a releasable liner, and/or throughan adhesive layer, depending on the desired effect. The articles of thepresent invention are particularly advantageous for delivering a fauxfinish to a surface in a single application step. Faux finishes are wellknown in the art and generally provide a non-homogeneous decorativeeffect, examples of which include, but are not limited to, marbleizing,mottling, stippling, streaking, ragging and the like. In one embodiment,the dry color component is provided in a noncontinuous or continuous,repeating or non-repeating pattern to provide a stencil-like effect on asurface.

The dry color component may exhibit gloss characteristics as desired. Inone embodiment of the invention, the dry color component exhibits glosscharacteristic of conventional architectural paints, such as flat,eggshell, satin, semi-gloss or gloss finishes, as desired. One ofordinary skill in the art will appreciate the difference between suchfinishes and high-gloss finishes such as are employed in, for example,the automotive industry. Gloss may be measured by specular reflectanceof a beam of light at an angle of 60°. Typically, the specularreflectance for the sheet of dry color component of the presentinvention is less than about 60 gloss units at 60°. Specular reflectancemay be measured using the test method described in GM Test SpecificationTM-204-A. The Byk-Mallinckrodt “multi-gloss” or “single gloss” glossmeters can be used for measuring specular gloss of the finished surface.Those gloss meters give values equivalent to those obtained from ASTMMethod D-523-57. Either gloss meter is used with gloss standardscovering the expected range of measurement, together with a piece ofpolished black glass plate of known refractive index. The gloss meter iscalibrated by setting it to read the gloss of a highly polished standardand then reading the gloss of a working standard having a valuepreferably in the range of the test panel. The second standard shouldagree within one unit of its assigned value. At least two readings aretaken on a different area of the test panel. These values are averagedif they agree within one unit. If the range is larger than one unit,additional regions are taken and a mean value is calculated. Desiredgloss characteristics may be obtained by use of particles included inthe dry color component sheet, a topcoat layer, post-treatment,texturization or the like in accordance with techniques known in theart.

Another benefit of low gloss surfaces is a reduced need for surfacepreparation prior to future applications of surface treatments that maybe desired to change color and/or appearance, or prior to refinishingthe surface with a fresh application of color treatment. In particular,high gloss surfaces, in general, tend to require roughness to beimparted to ensure good results when painting or applying othertreatments to the surface.

In specific embodiments, the sheet of dry color component comprises twoor more layers, at least one of which contains a color component toprovide a desired color effect. Additional layers may comprise atopcoat, for example comprising a transparent, translucent, pearlescentor opaque coating, for example providing a gloss, semi-gloss, satin,eggshell, or flat sheen or other optical effects such as diffusion,reflectance or the like, or other beneficial properties, a white backinglayer to provide intensity and/or consistency, an opacifying layer, orthe like, and combinations thereof. Another benefit of such additionallayers is that they can provide increased strength and/or flexibility tothe sheet.

In a specific embodiment, the dry color component comprises a dryarchitectural surface color component, i.e., a color componentparticularly adapted for application to an architectural surface. Suchdry color components typically exclude color components requiring notonly conventional drying but an additional curing step, for example, ahigh temperature curing step, the addition of a reactive curing agenttherein or the like. Thus, in one embodiment, the dry architecturalsurface color component is substantially free of cyanate curing agents,(meth)acrylate curing agents and cyanate-(meth)acrylate curing agentstypically employed in curable enamel paints, whereby the color componentcontains any such curing agents therein in an amount which is less thanthat required to effect measurable crosslinking of the color component.In more specific embodiments, any such curing agents are contained inthe color component in an amount less than about 0.0004% by weight.

As the dry color component is adapted to be applied to a surface in adry state, the sheet of dry color component is produced at amanufacturing location. The sheet of dry colorant may be formed usinglatex compositions, water-dispersible compositions, solvent-basedcompositions, ultraviolet curable compositions, or the like. As thesheet is produced at a manufacturing location, paint drying or curing isaffected within the manufacturing process and volatile organiccomponents or other byproducts from the compositions may be captured inthe manufacturing process. In one embodiment, these byproducts may bereclaimed or recycled as part of the manufacturing process.

The articles provide good opacity and coverage by application of asingle sheet of dry color component, providing consumers with cost andtime benefits. Preferably the articles exhibit an opacity index of atleast about 0.95 as measured according to ASTM D2805. Typically, in suchmeasurements, the article is carefully applied on a test surface, forexample the surface of a color contrast card such as a Leneta opacityform 2A, avoiding bubbles and wrinkles. In more specific embodiments,the articles exhibit an opacity index of at least about 0.98, and morespecifically at least about 0.995 as measured according to ASTM D2805.Substantially complete coverage, i.e., full hide, may be obtained evenover dark surfaces, stained surfaces and the like. If desired, one ormore layers or components of the article may include an additionalopacifying agent, for example one or more metals, metal oxides,minerals, or the like, or a combination thereof, to improve the opacityof the article. Examples of such opacifying agents include, but are notlimited to, titanium dioxide, carbon black, and the like. Suitableopacifying agents may be provided as clusters, powders, flakes,particles, or groupings of particles such as aggregates or agglomerates,or the like. Flakes having a minimum dimension of at least 0.02 micronsand an aspect ratio of about 100 to 1000 are desirable. Particles, forexample, titanium dioxide particles, that impart good opacificationpreferably have a dimension in the range of about 0.15 to 150 micronsand more preferably from about 0.20 to 50 microns. While the opacifyingagent may be provided in the sheet of dry color component, inalternative embodiments, the opacifying agent, if employed, may beincluded in the adhesive or a backing layer, or in one or more otherlayers as desired. While not wishing to be bound by theory, it isbelieved that many household stains, particularly oil-based stains,exhibit reduced surface energy and tend to repel wet paint, particularlywater-based wet paints, thereby making stains difficult to cover andoften requiring additional pretreatment steps. Wet water-based paintscan also cause flash rusting when water migrates from the paint to nailheads and the like. However, the dry color component sheets of thepresent invention are substantially free of a liquid carrier, wherebythe aforementioned problems associated with liquid carriers are avoided.Advantageously, stains can often be covered without pretreatment of thestained surface.

The dry color component advantageously exhibits a minimum level ofelasticity sufficient to allow bending, rolling, or similarmanipulations of the sheets without causing cracking, breaking or otherdamage to continuous areas of dry color component.

In one embodiment, the articles of the invention also exhibit less than50% elongation when measured according to ASTM D882 using a 1.0 inch(2.54 cm) wide sample and a 2.0 inch gauge length at a crosshead speedof 20 in/min (50.8 cm/min). Generally, elongation is measured at roomtemperature which, as used herein, refers to temperatures less thanabout 100° F. (38° C.). Typically, the elongation as described above isexhibited at temperatures of from abut 40° F. (4° C.) to about 95° F.(35° C.), more specifically at about 60° F. (15° C.) to about 80° F.(27° C.). In further embodiments, the articles exhibit 25% or lesselongation, according to ASTM D882 as described.

The sheet of dry color component may also exhibit sufficientconformability to adapt to the form of the surface to be colored. Inaddition, the sheet of dry color component may be sufficientlyconformable to allow the articles to be easily manipulated around and/orinto corners and other three-dimensional configurations. Further, thesheet of the dry color component may be microconformable. As usedherein, microconformability refers to the ability of the articles tobecome similar in form or character to the surface to which they areadhered, whereby, upon application, the sheet of dry color componentwill closely mimic the texture of the underlying surface to provide apaint-like appearance. The conformability and microconformability arepreferably exhibited at room temperature as defined above.

In the embodiment shown in FIG. 1, the article 10 for applying color ona surface is free of a releasable liner and is free of a carrier sheet.As used herein, the term “releasable liner” is generally used to referto a sheet which is removable and is intended and adapted for removalshortly before or upon application of the sheet of dry color componentto the desired surface. On the other hand, as used herein, carrier sheetis used to refer to a sheet which is intended and adapted forapplication to a surface, typically between the surface and a layerproviding a decorative effect, to provide structural support. A commoncarrier comprises, for example, a wallpaper backing sheet. Carrierlayers are typically significantly greater than 3 mils (0.08 mm) inthickness and therefore are significantly distinguishable from the sheetof dry color component and the articles of the present invention. Thus,in the embodiment of FIG. 1, neither a carrier sheet nor a releasableliner is employed. In a further embodiment, the article is free ofcellulosic materials, particularly cellulosic substrates commonlyemployed in wallpaper carrier layers. In a more specific embodiment, thearticle 10 consists essentially of the sheet 12 of dry color componentand the adhesive 14 on the surface 16 of the sheet 12 and does notinclude any other component which would materially affect the use orproperties of the article.

In another embodiment, the sheet 12 of dry color component comprises areinforcing component. The reinforcing component may be used to providestrength or structural integrity to the sheet material and/or to providethe sheet material with increased thickness or body to facilitatehandling and/or use of the article. Other advantages resulting from theuse of a reinforcing component will be apparent in view of the presentdisclosure. The reinforcing component may comprise any additive whichachieves one or more of the intended reinforcing benefits. Preferably,the reinforcing component does not disadvantageously alter the rheologyof the sheet of dry color component, whereby the sheet exhibitssufficient elasticity to allow bending, rolling and the like withoutcausing cracking or other damage to the dry color component sheet.Examples of suitable reinforcing components include, but are not limitedto, filaments, fibers, films, nonwovens, scrim, threads, sheets and thelike, or a combination thereof, and may be formed of any suitablematerial, including polymers, metals, cellulosic materials, glass,ceramics, and the like. The reinforcing component is distinguishablefrom a carrier sheet or layer as the reinforcing component is providedwithin the sheet of dry colorant and is not adapted or intended forarrangement between the sheet of dry colorant and a wall surface. Incontrast, a carrier sheet, as noted above, is intended and adapted forapplication to a surface between the surface and a layer providing acolor effect, such as in wall paper.

The reinforcing component may be provided in the sheet 12 in a patternedmanner, for example, as a thinly woven structure, or in a non-patterned,non-woven manner, using any desirable technique, for example casting,mixing, coating or spraying. In one embodiment, the reinforcingcomponent will be of a sufficiently small dimension so as to not providean undesirable irregular surface when the sheet of dry color componentis applied to the surface for which a color benefit is desired. Forexample, in such embodiments, suitable reinforcing components shouldhave a thickness dimension not greater than about 75% of the thicknessof the sheet of dry color component. In alternate embodiments, thereinforcing component may be of sufficient thickness to provide surfacetexturing of the sheet of dry color component. FIG. 1A shows an article10A comprising a sheet 12A of dry color component and an adhesive 14A.The sheet 12A comprises a reinforcing component 11 and layers 13 of drycolor component.

Adhesive, as used herein, refers to a substance which is adapted toadhere the article of the invention to a surface at room temperaturewhich, as used herein, generally refers to temperatures less than about100° F. (38° C.). Typically, for use on architectural surfaces, theadhesive will exhibit the required adhering effect at temperatures in arange of from about 40° F. (4° C.) to about 95° F. (35° C.).Additionally, the adhesive exhibits its adhering effect at lowapplication pressures, thereby allowing application and adherence of thearticles of the invention to a surface to be colored by hand or withsimple tools. In one embodiment, the adhesive is adapted to adhere thearticle to a surface to be colored by application of a pressure of lessthan about 50 lb/in² (3.5 kg/m²) more specifically less than about 30lb/in² (2.1 kg/m²), and even more specifically less than about 20 lb/in²(1.4 kg/m²). In a further embodiment, the adhesive is adapted to adherethe article to a surface to be colored by application of a pressure offrom about 3 lb/in² (0.21 kg/m²) to about 10 lb/in² (0.7 kg/m²).

In FIG. 1, the adhesive 14 is illustrated as a layer on the surface 16of the sheet 12. The adhesive may be provided in layer form asillustrated, or may be provided in any continuous or non-continuousconfiguration as desired. The adhesive serves to adhere the sheet of drycolor component to the surface to be colored. Preferably, the adhesiveis of a character and is provided in an amount to allow repositioning ofthe article when the article is initially applied to a surface, suchthat the sheet of dry color component may be temporarily adhered to asurface to be colored and, if improperly positioned, may be repositionedor even removed from the surface and reapplied for proper positioning,and such that once proper positioning of the sheet of dry colorcomponent has been obtained, the sheet of dry color component may bepermanently adhered to the surface. Thus, in one embodiment, theadhesive is adapted to exhibit an initial tack in response to a firstcondition and a subsequent tack greater than the initial tack inresponse to a second condition.

An initial low tack suitable to allow repositioning is about 100grams/inch or less, more preferably in the range of from about 25grams/inch to about 50 grams/inch, as measured in a 180° angle peel testusing a 1.0 inch wide peel strip according to ASTM D3330 and/or PSTC-1.The subsequent tack is greater than the initial tack and in a specificembodiment provides a substantially permanent adhesion or bond betweenthe sheet of dry color component and the surface.

In one embodiment, the first condition may comprise a first applicationpressure which causes the adhesive to exhibit the initial tack, whilethe second condition may comprise a second, greater application pressurewhich causes the adhesive to exhibit a second greater tack. In analternate embodiment, the first condition may comprise a first period oftime after application of the article to a surface, during which periodof time the adhesive exhibits a level of tack allowing repositioning,and the second condition is the period of time occurring afterexpiration of the first period of time, i.e., a “second period of time”.After the first period of time, the adhesive exhibits a level of tackthat inhibits or prevents repositioning. The period of time during whichthe tack increases from a repositionable level to the substantiallypermanent level is a matter of choice that can be designed into theproduct by selection of adhesive, in accordance with ordinary skill inthe adhesive art. In certain embodiments, the first time period will befrom about 2 hours to about 24 hours. Thus, in this embodiment, theadhesive may be provided such that the article is positioned on andadhered to a surface using a single pressure, applied by hand or with asimple applicator tool, and the permanence of the adhesive tackincreases over time once the article has been applied on a surface.

The adhesive component of the articles of the invention is a dryadhesive, i.e., an adhesive which is substantially free of a liquidcarrier such that it is immobilized on the sheet of dry color componentand does not drip therefrom. Exemplary, but non-limiting adhesivesinclude hot melt-, pressure sensitive-, water based-, water borne-,solvent based-, ultraviolet-and e-beam cured adhesives, and combinationsthereof. In one embodiment, the adhesive comprises a pressure sensitiveadhesive, for example, hot melt pressure sensitive adhesive, orwater-based or -borne pressure sensitive adhesive, for example a liquidemulsion pressure sensitive adhesive, which may be applied to a sheet ofcolor component and then dried to provide the articles of the presentinvention. Alternatively, the adhesive may be a static adhesive, forexample an electrostatic adhesive. It is preferred that the adhesivecause the sheet of dry paint and the substrate to have a final bondstrength of greater than about 100 grams/in, more specifically greaterthan about 150 grams/in, and even more specifically greater than about200 grams/in, as measured according to ASTM D3330 as described aboveusing a 1 inch wide peel strip.

While the adhesive may allow initial repositioning of the sheet of drycolor component, the adhesive preferably provides an at leastsubstantially permanent bond between the dry color component and thesurface to which the color effect is provided upon completion of theapplication process and curing of the adhesive. A substantiallypermanent bond is one that is not broken upon casual contact, lightwashing or the like. The at least substantially permanent bond may beprovided by removable adhesion, whereby the dry color component may beremoved from the surface without destruction of the sheet of dry colorcomponent. Alternatively, the substantially permanent bond may beprovided by latent permanent adhesion, whereby the sheet of dry colorcomponent may not be removed without destruction of the sheet.

In one embodiment, the adhesive is a pressure activated adhesive whereinthe adhesive tack is lower at low application pressures, therebyallowing initial repositioning of the sheet of dry color component on asurface without damaging the sheet of dry color component, but uponapplication of higher pressure, the adhesive exhibits greater tackwhereby a more permanent bond is formed between the sheet of dry colorcomponent and the surface to which it is applied, whereby the sheet ofdry color component is substantially permanently attached to thesurface, i.e., the sheet does not spontaneously separate and is notremoved upon casual contact, light washing or the like. Various pressuresensitive adhesives are known in the art and may be used in the articlesof the present invention. Such pressure sensitive adhesives may beprovided at a low coating weight or in a patterned or textured manner inorder to allow repositioning while providing latent permanent adhesion.

Examples of pressure sensitive adhesives include adhesives containingmicrospheres, employed in one, two or more layers. Such microspheres canbe, for example, breakable or deformable upon application of force tothe adhesive or article. Compositions containing breakable or deformablemicrospheres are described, for example, in the Erwin U.S. Pat. No.3,314,838 and the Danielson et al U.S. Pat. No. 3,331,729. Adhesivescontaining microspheres are commercially available, one example of whichis available under the tradename Controltac® from 3M Company. Pressuresentitive adhesives are also disclosed, for example, in the Questel etal U.S. Pat. No. 6,020,062. Additional formulations forpressure-sensitive adhesive compositions are disclosed in the BlackwellU.S. Pat. No. 5,073,457 and the Sagoff et al U.S. Pat. No. 4,151,319,which adhesives provide repositioning and latent permanent adhesion, andthe Reaves et al U.S. Pat. No. 5,939,479, disclosing an adhesive whichprovides repositioning adhesion. Additional pressure-sensitive adhesivesare commercially available and include Fasson® 2001, a latent permanentadhesion product commercially available from Avery Dennison.

The tack of the adhesive may also be varied as described above byapplication of a blocking agent on the exposed surface of the adhesive.The blocking agent has the affect of lowering the initial tack of theadhesive at the exposed surface of the adhesive. Thus, the blockingagent as defined herein lowers the low pressure tack of an adhesivewhile permitting high tack to be achieved with the application of higherpressure which displaces the blocking agent. Suitable blocking agentscan be solid structures that cover at least a portion of the surface andextend over the outer surface of the adhesive. The blocking agents mayform a plurality of discrete structures or may form an interconnectednetwork. One of ordinary skill in the art will recognize varioussuitable blocking agents for use in such an embodiment.

In one embodiment, the blocking agent may comprise compositionscontaining repositionable microspheres. Such compositions may beprovided in one or more layers as described in the Parrotta U.S. Pat.No. 4,376,151. Examples of additional blocking agents include, but arenot limited to, those disclosed in the Ochi U.S. Pat. No. 4,556,595,clusters, powders or particles of, for example, starch, including butnot limited to potato starch or corn starch, talc, silicon dioxide,titanium dioxide, zeolite, or other minerals, polymers or polymerprills, glass or ceramic beads, or the like. The amount and size of suchmaterials will depend on the type and tack of individual adhesives. Inone example, talc particles having an average particle size of about 0.1mm are applied in an amount of about 2 to about 6 g/m² to sufficientlyreduce initial tack to allow repositioning without a proportionatedecrease in final tack. In another example, silicon dioxide particleshaving an average particle size of about 25 nm are applied in an amountof from about 1 to about 3 μm². In yet another example, titanium dioxideparticles having an average particle size of about 50 nm and are appliedin an amount of from about 1 to about 3 g/m². The blocking agent may beapplied in a uniform or nonuniform pattern as desired.

In one embodiment of the articles of the invention, the sheet of drycolorant is permanently adhered to the surface such that it may not beremoved without damaging the sheet of dry color component. In a furtherembodiment of the articles of the invention, the sheet of dry colorantis permanently adhered to the surface such that it cannot be removed bycasual contact, washing or the like, but it may be removed withoutsubstantial destruction of the sheet.

In one embodiment, the sheet 12 of dry color component may furtherinclude a release agent coating at its outer surface 15, i.e., on thesurface of the sheet 12 which is opposite, i.e., not adjacent, theadhesive 14 as shown in FIG. 1. Suitable release agents are discussed indetail below. Alternatively, or in addition, the sheet 12 of dry colorcomponent may include a top or outer, exposed film or coating at itssurface, hereinafter a “topcoat.” The topcoat may comprise atransparent, translucent, pearlescent, opaque or other formulation asnecessary to provide a desired optical effect, and/or to provide thesheet of dry color component with increased protection, stiffness and/orstructural support. For example, the topcoat may be employed to providea desired sheen to the dry color component, i.e., flat, satin, eggshell,semi-gloss or gloss, to increase the opacity, diffusion or reflectanceof the dry color component upon application to a surface, or the like.In further embodiments, the topcoat may include one or more additionalcomponents which provide the sheet of dry color component with improveddurability, chip resistance, washability, stain repellence, faderesistance, including ultraviolet light fade resistance, fluorescence,phosphorescence, bactericidal properties, fragrance, odor removal,non-permanent writability (allowing erasure or washing to remove), noiseand/or heat insulation, conductivity, static dissipation, and/orenvironmental interaction, for example allowing shade or color changebased on temperature or the like.

The topcoat is provided at the outer surface of the sheet 12 and may bepermanently or temporarily adhered to the underlying layer. FIG. 1Bshows an article 10B comprising a sheet 12B of dry color component andan adhesive 14B. The sheet 12B includes a layer 13B of dry colorcomponent and a topcoat 17. The topcoat 17 may similarly be providedwith a release agent coating at its outer surface 19. The topcoat may beformed of any suitable material, examples of which include polymers, forexample polyurethanes, polyvinyl chlorides, polyvinylidine fluorides,polyacrylates, cellulosic materials and the like, as well as blendsthereof, and optionally various particles for altering optical effectsor texture of the surface of the dry color component sheet. Specificexamples of topcoats include polyurethane and blends of polyacrylate andpolyvinylidine chloride. The topcoat can be transparent. In otherembodiments, the topcoat can be translucent, or at least partiallyopaque. Other topcoat materials suitable for use herein will be apparentto those of ordinary skill in the art.

In one embodiment, the topcoat is configured, either microscopically ormacroscopically, to allow the sheet of dry color component and adhesiveto provide a surface covering with a desired WVTR, for example greaterthan 1 g-μm/cm²/24 hrs, at 100% relative humidity and 40° C., asmeasured according to ASTM F1249-90. The topcoat may, for example, beprovided with perforations, pores, orifices or the like, or may beformed of a material exhibiting such WVTR. In one embodiment, thetopcoat is formed of a polymeric coating such as, but not limited to,polyurethane coating, having a sufficiently small thickness, forexample, of about 0.5 mils (0.013 mm) or less, and in a furtherembodiment, of about 0.25 mils (0.007 mm) or less, to allow the desiredWVTR.

FIG. 2 sets forth a schematic diagram of another embodiment of anarticle for applying color on a surface according to the invention. Thearticle 20 includes a sheet 22 of dry color component, an adhesive 24 onthe surface 26 of the sheet of dry color component and a releasableliner 28. The sheet 22 of dry color component is arranged between thereleasable liner 28 and the adhesive 24. The releasable liner 28 may beincluded in order to provide structural support and/or strength to thesheet 22 of dry color component, for example when the releasable lineris in film form, and/or to facilitate handling of the article duringmanufacture, storage and use. The releasable liner is adapted forremoval from the sheet of dry color component prior to or uponapplication of the sheet of dry color component to a surface to becolored. Typically, the releasable liner will be removed from the sheetof dry paint by peeling therefrom. As shown in FIG. 2, the releasableliner may be provided with a tab 32 which extends beyond the sheet ofdry color component to assist peeling of the liner 28 from the sheet 22of dry color component. Alternatively, the release liner may be removedusing an adhesive tape that may be applied to the coiner (or other edge)of the release liner and then pulled off, for example, after the sheetof dry colorant has been applied to a surface. The adhesive tape pullsthe release liner off the sheet of dry colorant, leaving the sheet ofdry colorant attached to the surface. The adhesive tape does not damagethe surface of the sheet of dry colorant or adjacent sheets of drycolorant. An example of a suitable adhesive tape is Temp RL™ tapecommercially available from Saint Gobain. In a further embodiment, thearticles may be adapted for use with a simple separator tool whichfacilitates separation of the releasable liner from the sheet of drycolorant. Such a tool may be provided with at least one straight edgewhich acts to separate the releasable liner at an edge of the article.

In one embodiment, the articles of the invention include a releasableliner adjacent the sheet of dry color component and, in the planarconfiguration of the articles as shown in FIG. 2, are free of areleasable liner on the adhesive. Thus, in the embodiment of FIG. 2, theupper surface of the adhesive 24 is free of a releasable liner when thearticle is in a planar, nonrolled configuration. When an article asshown in FIG. 2 is in a roll form, the releasable liner 28 will bepositioned adjacent, and possibly contacting, the exposed adhesive 24and therefore may provide a release surface to allow unrolling of thearticle without interference of the adhesive, as is described in greaterdetail below.

In further embodiments, the articles may comprise two or more releasableliners. For example, the article 20A of FIG. 2A comprises a sheet. 22Aof dry color component, including layer 23 of dry color component andtopcoat layer 27, and an adhesive 24A, in combination with a releasableliner 28A on the surface of the sheet 22A of dry color component whichis opposite that of the adhesive 24A, and a releasable liner 36 on theadhesive 24A. The topcoat layer 27 on the sheet 22A of dry colorcomponent may provide the color component with additional properties asdiscussed above, between the sheet 22A and the releasable liner 28A.

The releasable liner may be formed of any material which provides thedesired structural support or strength to the sheet of dry colorcomponent to facilitate manufacture, handling and/or application of thearticle to a desired surface. Typically, the releasable liner will havea combination of basis weight, thickness and rigidity to provide thedesired structural support and/or strength to the article. For example,the releasable liner may be formed of a polymer material, for example asa thin polymeric film, as a woven sheet, or as a non-woven sheet, or ofa fibrous ligno-cellulosic material such as paper. In one embodiment,the releasable liner comprises a polymer film. Conveniently, the sheetof dry color component may be formed on the polymer film, for example bycoating or printing the color component directly on the polymer filmsurface. The release surface may be relatively flat and smooth but mayalso be textured or three dimensionally configured via embossing,microembossing, thermoforming with heat and pressure, vacuum forming, orother approaches known to those skilled in the art.

In one embodiment, the releasable liner is formed of a material which isinherently releasable from the sheet of dry color component. Suitablematerials which may be used to form an inherently releasable linerinclude, but are not limited to, silicone-based polymers, includingcopolymers thereof, fluorocarbon polymers, including copolymers thereof,fluoro-acrylate polymers, including copolymers thereof, and polymers,including copolymers, which include a release additive, for example asilicone or fluorocarbon additive, therein. Examples of polymerscontaining such additives include polyolefins, for example, polyethylenehomopolymers and copolymers, polypropylene homopolymers and copolymersand polymethyl pentene homopolymers and copolymers, polystyrenehomopolymers and copolymers, polyester homopolymers and copolymers, forexample polyethylene terephthalates (PET), and polyamide homopolymersand copolymers, including one or more release additives such as siliconeoils, silicone surfactants, silicone homopolymers and copolymers,fluorocarbon oils, fluorocarbon surfactants, fluorocarbon homopolymersand copolymers, for example fluoro-acrylate homopolymers and copolymers,and mixtures thereof. Suitable release additives may alone be liquid orsolid at room temperature. Suitable release additives may be liquid orsolid at room temperature. U.S. Pat. Nos. 5,476,901 and 5,641,835, eachof which is incorporated herein by reference, disclose examples ofsuitable silicone-polyolefin copolymers suitable for use in forming areleasable liner in the articles of the present invention. U.S. Pat. No.5,728,469, incorporated herein by reference, discloses additionalsuitable block copolymer release materials for pressure sensitiveadhesives. European Patent Application EP 1 018 533 A2, incorporatedherein by reference, further discloses silicone-containing resinsuitable for use as a release layer.

Alternatively, or in addition, a release agent may be provided betweenthe releasable liner and the sheet of dry color component in order toassist removal of the releasable liner from the sheet of dry colorcomponent. For example, in the article of FIG. 2, the release agent isprovided at interface 30 between the sheet 22 of dry color component andthe releasable liner 28. The release agent may be provided as a coatingor as a separate film layer in the article. In a specific embodiment,the release agent is provided as a coating on one or both of theinterface surfaces between the sheet of dry color component and thereleasable liner. Various release agents are known in the art and aresuitable for use herein and include, but are not limited to, siliconeoil, silicone surfactant, silicone homopolymer or copolymer,fluorocarbon oil, fluorocarbon surfactant, fluorocarbon homopolymer orcopolymer, for example fluoro-acrylate homopolymers and copolymers, andmixtures thereof. The release agent may be provided as a coating on thesurface of the dry sheet of color component at the interface 30 adjacentthe releasable liner, as a coating on the releasable liner surface of atthe interface 30 adjacent sheet of dry color component, as a layerbetween the sheet of dry color component and the releasable liner, orany combination thereof. Such coatings may be continuous ornon-continuous as is necessary in order for the liner to be releasablefrom the sheet of dry color component without damage to the surface ofthe sheet of dry color component. In one embodiment, the release agentcomprises a polymeric material, for example a polysilicone, which isapplied as a continuous or non-continuous coating on the surface of thereleasable liner 28 at the interface 30.

In one embodiment, the releasable liner may further include a releaseagent at its outer surface 34, i.e., on the surface of the liner whichis opposite, i.e., not adjacent, the sheet of dry color component. Inthe embodiment of the article of FIG. 2 wherein the releasable liner 28is provided with a release agent on the surface 34 which is opposite tothe sheet of dry color component, the release agent on surface 34prevents the surface 34 from adhering to the adhesive 24 during storage,handling and use of the article. For example, the provision of a releaseagent on surface 34 facilitates storage of the article in a rolledmanner. Similarly, in the embodiment of FIG. 1, the surface 15 of thesheet 12 of dry color component may be provided with a release agent toprevent adhesion of the surface 15 with adhesive 14 during storage,handling and use of the article 10. Release agents of the type discussedabove are suitable for application to surface 15 or surface 34.

In the embodiment of FIG. 2, the adhesive 14 may include a blockingagent of the type discussed above, wherein the blocking agent rendersthe adhesive pressure activatable, whereby the adhesive tack is reducedat low application pressures to allow initial repositioning of thearticle on a surface to be colored, while upon application of higherpressure, the adhesive permanently bonds the sheet of dry colorcomponent to the surface.

In an alternate embodiment, the releasable liner 28 is arranged on thesurface of the sheet 22 of dry color component at interface 30 withoutany additional layer, coating or component therebetween. In thisembodiment, the releasable liner 28 is preferably formed of a materialwhich inherently releases from the surface of the sheet 22 of dry colorcomponent at the interface 30. This embodiment eliminates any residue ofrelease agent on the surface of the sheet 22 of dry color component oncethe releasable liner 28 is removed therefrom.

FIG. 3 sets forth a schematic diagram of yet another embodiment of anarticle for applying color on a surface according to the invention. Thearticle 40 includes a sheet 42 of dry color component, including a layer43 of dry color component and a backing layer 45 on one surface 46 ofthe layer 43 of dry color component. An adhesive 44 is provided on thesurface 47 of the backing layer 45. The article comprising the sheet 42and the adhesive 44 has a thickness of about 3 mils (0.08 mm) or less,more specifically about 2 mils (0.05 mm) or less, and even morespecifically about 1 mil (0.3 mm) or less. Thus, the article of thisembodiment is significantly thinner than conventional wallpaper productswhich typically have significantly thicker carrier substrates. Thebacking layer 45 may be included, for example, in order to providestructural support and/or strength to the sheet 42 of dry colorcomponent, to provide additional opacifying, whitening or colorstrengthening effects, and/or to facilitate handling of the articleduring storage and use. The backing layer may be formed of any suitablethin material, examples of which include, but are not limited to paperand other cellulosic materials, polymer films and woven or nonwovenfabrics, textile fabrics, glass or ceramic fabrics, metallized layer(s),and the like. In one embodiment, the backing layer may provide increasedopacity to the article upon application to a surface to be colored. Forexample, the backing layer may include titanium dioxide, metal filler orthe like to provide increased opacity. Preferably, the backing layerwill exhibit sufficient flexibility to allow bending, rolling and othersimilar manipulations of the article.

In one embodiment, the backing layer comprises a metallized film, i.e.,a laminate of two or more polymer films having a metallized layer orcoating between two internal surfaces thereof. As shown in FIG. 3, thebacking layer 45 may comprise a laminate of two polymer films 50, 52,for example formed of polyethylene terephthalate, having a metallizedcoating 54, for example formed of silver ink, a metal oxide, aluminum,stainless steel or the like, therebetween. One example of an aluminumink is Metalure®, commercially available from Eckart America Division(Painesville, Ohio, USA) of Eckart Werke GmbH and Company (manufacturedby Avery Dennison Corp.). The metallized coating may be continuous ordiscontinuous, and patterned or nonpatterned as desired. Preferably,polymer film 52 is very thin and may comprise a tie layer or coating tothe sheet of dry color component. The polymer film 50 may provide asurface for the metallized coating 54 and may provide structural supportto the article. In one embodiment, the sheet 42 of dry color componentmay further include a release agent coating at its outer surface, i.e.,on the surface of the sheet 42 which is opposite, i.e., not adjacent to,the surface including the backing layer 45. In yet another embodiment,one of the layers of polymer film 50 or 52 may be eliminated providingan article that is even thinner, yet remains opaque.

The size of the articles according to the present invention by width andlength may vary in accordance with the dimensions of surfaces to becolored. For example, the articles may be provided in relatively largelengths suitable for coloring an entire length or multiple lengths of aninterior architectural surface. Sheets of such lengths may be stored inroll form. Alternatively, the articles may be provided in smallersheets, for example in tile size to accommodate small areas. Similarly,articles may be provided in strip or smaller sized form for use in areasof smaller dimensions, for example, as trim around moldings, borders,accent pieces (e.g., stencils), outlets, corners and areas adjacent tosurfaces which are not intended for color application. Smaller sizedarticles may also be convenient for repairing damaged areas.

The articles according to the present invention allow one to apply coloron a surface by delivering dry color component to the surface. Morespecifically, the articles allow one to provide a substantiallypermanent color effect on a surface. Advantageously, the dry colorcomponent is delivered to the surface without the use of wet tools fordelivering the color component, for example without the use of wet paintapplicators, such as paint brushes, paint sprayers or paint rollers, orpaint trays, without the use of mess protection such as taping or dropcloths, without the use of color component cleaning materials commonlyrequired for washing paint applicators, and/or without the use of liquidvolatile organic component vehicles such as oil-based solvents for thecolor component. As a result, a color effect may be obtained morequickly and easily, while avoiding many problems associated with wetapplication as discussed herein.

Thus, in one embodiment of the present methods, an article comprising adry color component is applied to an architectural surface. Afterapplication and upon removal of any releasable liners included in thearticle, the remaining portion of the article, for example the dry colorcomponent and any adhering means, i.e., adhesive, has a thickness ofabout 3 mils or less.

In a preferred embodiment of the present methods, the dry colorcomponent is delivered to the surface in the form of a sheet of drycolor component as discussed above. Preferably, the sheet of dry colorcomponent has an adhesive on one surface thereof. The methods accordingto the invention may further comprise the step of initially adhering thedelivered dry color component to the surface, for example by exertinglight pressure on the sheet of dry color component to temporarily bondthe sheet of dry color component to the surface to be colored,optionally adjusting the position or alignment of the sheet, andexerting increased pressure on the sheet of dry color component topermanently bond the sheet of dry color component to the surface to becolored. For example, when the sheet of dry color component is providedin an article 10 as described in FIG. 1, pressure may be applied tosurface 15 of the article to adhere the adhesive 14 to a surface to becolored. In the article 20 of FIG. 2, pressure is applied to surface 34as adhesive 24 contacts the surface to be colored in order to adhere thearticle 20 including the sheet 22 of dry color component to a surface tobe colored.

The articles of the invention may be applied to a surface merely by handplacement or with the use of a simple applicator, for example a wallpaper roller, and/or dispenser, or other tool. Similarly, any pressurerequired for adhesion of the articles may be applied by hand or with atool. Such pressure may be applied in a single pass or by two or morepasses over the article.

The articles and methods according to the invention provide improvedmeans for providing color to a surface, for example an architecturalsurface such as an interior wall, and avoid many of the disadvantagesassociated with conventional wet painting and wall papering. The risk ofpaint spills and splatters and the risk of painting undesirable surfacesis eliminated as the dry color component such as paint is immobilized orcontained prior to and during application. Thus, taping, drop cloths andother protective measures commonly employed for floors, furniture andadjacent areas are not required. Additionally, the articles and methodsallow the coloring to be achieved in increments of time and do notrequire a continuous large block of time to perform. Similarly,application may be interrupted without inconvenience. Further, since thecolor component is immobilized or contained in the articles according tothe invention, the overall amount of color component needed to achieve adesired result is reduced as compared with conventional wet paintingwherein various collateral surfaces of applicators, protective tapes,drop cloths and the like receive excess paint. Moreover, since thearticles may be repositioned prior to permanent bonding, preciselocation is allowed, and, since the articles are substantially free ofliquid carriers, shrinking of the sheets after application, as commonlyoccurs with wallpapers, is avoided. Thus, edge matching of adjacentsheets may be easily obtained. Alternatively, edge matching issues maybe avoided merely by overlapping adjacent sheets.

In view of the above, it will be apparent that the articles according tothe present invention may be formed by a variety of methods andtechniques. One such method is disclosed herein for illustrativepurposes only. More particularly, with reference to FIG. 4, a small,laboratory scale, semi-automated process is shown. A releasable liner100 is provided in roll form and is unrolled to travel through assembly102 via rollers 104, 106, 108, 110, 112 and 114 to form a completedarticle 116 which is wound on roll 118. As will be described in furtherdetail below, trimmed portions 120 are directed to roll 122. Thereleasable liner 100 is pulled as a web 101 through the assembly by acombination of the rolls 118 and 122 and a conveyer 124, for example avacuum conveyor. A suitable vacuum conveyor may comprise a continuousconveyor belt with two pulleys having an array of spaced holes that areexposed to the vacuum chamber immediately below. Negative pressure(vacuum) is created by a forced air blower. As the belt passes over thechamber, a negative pressure is created at each hole such that thereleasable liner 100 is securely held to the belt as it passes over thebelt. This effect assists in preventing wrinkles in the releasable liner100 as the applied color component dries. The vacuum conveyor belt speedmay be matched to that of the drive rolls 118 and 122 driven by a drive119. The shaft of a roller 126 from which the releasable liner 100 issupplied is connected with a friction clutch 128 which may be adjustedto obtain sufficient tension in the web 101 for smooth travel throughthe process. A Fife guiding unit 130 may be provided to track the webtravel through the assembly.

A color component such as wet paint is applied to the web 101 of thereleasable liner adjacent roller 106 using an applicator 132. The paintor other color component may be water-based or solvent-based as desired,In one embodiment, the applicator 132 comprises a #50 wire wound rodwhich may be held against the roller 106 by spring tension or the likesuch that the web 101 passes between the roller 106 and the applicator132. The color component such as paint is introduced at the upstreamside of the wire wound rod applicator 132 by a manifold 134. Themanifold is fed by tubing 136 from a peristaltic pump 138 which drawsthe wet paint from a reservoir 140. To form the sheet of dry colorcomponent, the paint is dried on the web 101, for example as it passesover the vacuum conveyor 124 by the use of dryers. In the embodiment ofFIG. 4, the dryers comprise two infrared heaters 142 which are aided bya forced ambient air duct 144. The air duct 144 may conveniently blowthe exhaust from the vacuum conveyor 124. One skilled in the art willreadily appreciated that solvent or other carrier removed during thedrying process may be captured and recycled as desired. A sheet of drycolor component is thus formed on the releasable liner web.

An adhesive is then applied to the sheet of dry color component on thesurface opposite the releasable liner. For example, in the assembly 102of FIG. 4, adhesive is applied to the surface of the sheet of dry colorcomponent on the web 101 at roller 108 by an applicator 148 which maycomprise, for example, a #20 wire wound rod. The wire wound rodapplicator 148 may be held against the roller 108 by spring tension orthe like such that the web 101 passes between the roller and theapplicator. Liquid adhesive is introduced at the upstream side of thewire wound rod applicator 148 by a manifold 146. The manifold 146 is fedby tubing 150 from a peristaltic pump 152 which draws the liquidadhesive from a reservoir 154. The liquid adhesive in a reservoir 154 iscontinuously stirred by a mixer 156. With the adhesive applied thereon,the web 101 travels to an oscillating fabric covered roller 158 whichtraverses back and forth in the machine direction above a slider plate160 to impart a texture to the liquid adhesive applied to the sheet ofdry color component on the web 101. A textured adhesive may allow thearticle to be more easily repositioned prior to permanent bonding. Theadhesive is then dried, for example, by passing the web 101 under aninfrared heater 162 at roller 110.

In a preferred embodiment, the web 101 travels through rollers 112 and114, one of which is preferably in the form of a rotary cutting knife.In a more specific embodiment, roller 114 comprises two rotary cuttingknives which are arranged adjacent the edges of the web in order to trimthe web edges and provide the final article with the homogenous edges.In another embodiment, the roller 114 comprises a plurality of rotarycutting knife sets which are arranged so as to cut the web into two ormore strips to provide smaller sized articles adapted for applying colorto smaller sized areas as discussed above. The resulting article 116 isthen wound on the roll 118 while the trimmed edges 120 are wound on theroll 122. As set forth above, the described assembly 102 and preparationprocess is illustrative only and variations thereof will be apparent tothose skilled in the art. For example, release agents in the form ofcoatings, layers or the like may be provided in the process.Additionally, the sheet of dry color component may be provided in thefinal article in the absence of a release liner. For example, the sheetof dry color component may be formed on a processing web or forming beltand then separated from the processing web or forming belt prior tostorage in roll or sheet form.

In an alternate embodiment, the articles according to the invention asset forth, for example, in FIG. 2A may be formed using a modifiedversion of the process as described above wherein two releasable linerwebs are employed. For example, with reference to FIG. 2A, a topcoatcomposition for forming topcoat layer 27 may be applied to a releasableliner web by reverse roll, extrusion coating or the like techniques, anddried thereon, for example with heat. A color component may then beapplied to the dried topcoat layer, for example by reverse roll, gravurecoating, printing, or the like techniques, and dried with heat. Theadhesive may then be applied to a second releasable liner web, followedby laminating the releasable liner-topcoat-dry color component memberwith the adhesive-releasable liner member, with the dry color componentand adhesive in facing relationship. Heat may be provided throughoutthis process by any suitable means including convection or radiation,for example infrared, ultraviolet or the like. One of ordinary skill inthe art will also appreciate that this method may be used to provide anarticle including a single releasable liner, for example as set forth inFIG. 2, by merely removing the second releasable liner from the adhesiveonce the releasable liner-topcoat-dry color component member and theadhesive-releasable liner member have been assembled.

Additional or alternative apparatus and/or processing steps will beapparent to one skilled in the art in view of this description and arewithin the scope of the present invention. For example, the colorcomponent or adhesive could be applied as a single layer or in multiplelayers using a variety of known application techniques includingextrusion, spraying, printing, reverse roll, gravure coating, rollapplication and others known in the art. The layers may have the sameproperties or various layers, different from each other, may be employedto combine various properties such as color, strength, opacity, and thelike. A blocking agent as described above may be applied to the adhesivesurface and/or may be mixed with the adhesive. Heating may be providedby infrared, convection, or radiation apparatus or other techniquesknown in the art. Texturization may be provided on or in one or morelayers of the article.

The specific illustrations and embodiments described herein areexemplary only in nature and are not intended to be limiting of theinvention defined by the claims. Further embodiments and examples willbe apparent to one of ordinary skill in the art in view of thisspecification and are within the scope of the claimed invention.

1. An architectural surface covering product for applying color to anarchitectural surface, the architectural surface covering productcomprising a flexible and conformable film for application to anarchitectural surface in side-by-side sheets, which sheets may at leastpartially overlap, said architectural surface covering productcomprising: (a) a sheet of dry color component having two surfacescomprising an inside surface and an outside surface, said sheet of drycolor component comprising an opaque layer of dry paint; (b) arepositionable pressure sensitive adhesive on the inside surface of thesheet of dry color component; and (c) a releasable liner comprising afilm, said releasable liner being releasably adhered to the outsidesurface of the sheet of dry color component opposite the adhesive,wherein the sheet of dry color component and the adhesive have acombined thickness of less than or equal to about 3 mils, and the sheetof dry color component with the adhesive thereon exhibits an elongationof less than 50% when measured according to ASTM D882.
 2. Thearchitectural surface covering product of claim 1 wherein the adhesiveis tacky at a temperature range of between about 40° F. and 95° F., andhas a first tack after a first period of time for forming arepositionable bond, and a second tack after a second period of time,wherein the second period of time is longer than said first period oftime, and said second tack is greater than said first tack for forming asubstantially permanent bond.
 3. The architectural surface coveringproduct of claim 1 wherein the adhesive is tacky at a temperature rangeof between about 40° F. and 95° F., and has a first tack uponapplication of the adhesive to the surface with a first pressure forforming a repositionable bond, and a second tack upon application of asecond pressure to the adhesive, wherein said second pressure is greaterthan said first pressure, and said second tack is greater than saidfirst tack for forming a substantially permanent bond.
 4. Thearchitectural surface covering product of claim 1 wherein said adhesivewill adhere to the outside surface of the sheet of dry color componentof a second sheet of said architectural surface covering product, andsaid adhesive is repositionable with respect to the outside surface ofthe sheet of dry color component of said second sheet of saidarchitectural surface covering product without damaging saidarchitectural surface covering product or said second sheet of saidarchitectural surface covering product.
 5. The architectural surfacecovering product of claim 1 wherein said releasable liner has an innersurface and an outer surface, wherein the inner surface of saidreleasable liner is releasably adhered to the outside surface of thesheet of dry color component, and said architectural surface coveringproduct further comprises a release agent disposed on said outer surfaceof said releasable liner.
 6. The architectural surface covering productof claim 1 wherein said sheet of dry color component is extensible toallow bending and rolling without cracking, breaking, or other damage tothe sheet of dry color component.
 7. The architectural surface coveringproduct of claim 6 wherein the sheet of dry color component with theadhesive thereon exhibits an elongation of less than or equal to 25%when measured according to ASTM D882.
 8. An architectural surfacecovering product according to claim 1 wherein the combination of thesheet of dry color component and the adhesive has an opacity index of atleast about 0.98.
 9. An architectural surface covering product accordingto claim 1 wherein the sheet of dry color component has a specularreflectance of less than about 60 gloss units at 60 degrees.
 10. Thearchitectural surface covering product of claim 1 wherein the adhesivehas a length and a width and said opaque layer of dry paint comprises acontinuous layer of color that has a length and width that issubstantially coterminous with the length and width of the pressuresensitive adhesive.
 11. The architectural surface covering product ofclaim 1 wherein said architectural surface covering product is providedin roll form with a plurality of turns in which the releasable linerside of the product is in contact with the adhesive side of the product.12. The architectural surface covering product of claim 11 wherein saidadhesive has an inwardly-facing surface facing said sheet of dry colorcomponent, and an opposed outwardly-facing surface, and when saidarchitectural surface covering product is laid flat, theoutwardly-facing surface of said adhesive is free of any additionalreleasable liner covering said pressure sensitive adhesive.
 13. Anarchitectural surface covering product for applying color to anarchitectural surface, the architectural surface covering productcomprising a flexible and conformable film for application to anarchitectural surface in side-by-side sheets, which sheets at leastpartially overlap, said architectural surface covering productcomprising: (a) a sheet of dry color component having two surfacescomprising an inside surface and an outside surface, said sheet of drycolor component comprising an opaque layer of dry paint; (b) arepositionable pressure sensitive adhesive on the inside surface of thesheet of dry color component, said adhesive having a length and a width,wherein: (1) the adhesive is adapted to exhibit an initial tack inresponse to a first condition and a subsequent tack greater than theinitial tack in response to a second condition; wherein the subsequenttack is adapted to provide a substantially permanent bond of the sheetof dry color component to a surface; (2) said adhesive will adhere tothe outside surface of the sheet of dry color component of a secondsheet of said architectural surface covering product, and said adhesiveis repositionable with respect to the outside surface of the sheet ofdry color component of said second sheet of said architectural surfacecovering product without damaging said architectural surface coveringproduct or said second sheet of said architectural surface coveringproduct; and (c) a releasable liner comprising a film, having an innersurface and an outer surface, said inner surface of said releasableliner being releasably adhered to the outside surface of the sheet ofdry color component opposite the adhesive, wherein: (i) the sheet of drycolor component and the adhesive have a combined thickness of less thanor equal to about 3 mils; (ii) the sheet of dry color component with theadhesive thereon is extensible to allow bending and rolling withoutcracking, breaking, or other damage to the sheet of dry color componentand exhibits an elongation of less than 50% when measured according toASTM D882; (iii) the sheet of dry color component has a specularreflectance of less than about 60 gloss units at 60 degrees; and (iv)said architectural surface covering product is free of any additionalreleasable liner covering said pressure sensitive adhesive.
 14. Thearchitectural surface covering product of claim 13 further comprising arelease agent disposed on said outer surface of said releasable liner.15. The architectural surface covering product of claim 13 wherein thesheet of dry color component with the adhesive thereon exhibits anelongation of less than or equal to 25% when measured according to ASTMD882.
 16. The architectural surface covering product of claim 13 whereinthe combination of the sheet of dry color component and the adhesive hasan opacity index of at least about 0.98.
 17. The architectural surfacecovering product of claim 13 wherein said opaque layer of dry paintcomprises a continuous layer of color that has a length and width thatis substantially coterminous with the length and width of the pressuresensitive adhesive.
 18. An architectural surface covering product forapplying color to an architectural surface, the architectural surfacecovering product comprising a flexible and conformable film forapplication to an architectural surface in side-by-side sheets, whichsheets at least partially overlap, to form a continuous layer of coloralong the length and across the width of the architectural surface, saidarchitectural surface covering product comprising: (a) a sheet of drycolor component having two surfaces comprising an inside surface and anoutside surface, said sheet of dry color component comprising an opaquelayer of dry paint; (b) a repositionable pressure sensitive adhesive onthe inside surface of the sheet of dry color component, said adhesivehaving a length and a width, wherein: (1) the adhesive is adapted toexhibit an initial tack in response to a first condition and asubsequent tack greater than the initial tack in response to a secondcondition; wherein the subsequent tack is adapted to provide asubstantially permanent bond of the sheet of dry color component to asurface; (2) said adhesive will adhere to the outside surface of thesheet of dry color component of a second sheet of said architecturalsurface covering product, and said adhesive is repositionable withrespect to the outside surface of the sheet of dry color component ofsaid second sheet of said architectural surface covering product withoutdamaging said architectural surface covering product or said secondsheet of said architectural surface covering product; (c) a releasableliner comprising a film, having an inner surface and an outer surface,said inner surface of said releasable liner being releasably adhered tothe outside surface of the sheet of dry color component opposite theadhesive; and (d) a release agent, said release agent being disposed onsaid outer surface of said releasable liner, wherein: (ii) the sheet ofdry color component and the adhesive have a combined thickness of lessthan or equal to about 3 mils; (ii) the sheet of dry color componentwith the adhesive thereon is extensible to allow bending and rollingwithout cracking, breaking, or other damage to the sheet of dry colorcomponent and exhibits an elongation of less than 50% when measuredaccording to ASTM D882; (iii) the combination of the sheet of dry colorcomponent and the adhesive have an opacity index of at least about 0.98;(iv) the sheet of dry color component has a specular reflectance of lessthan about 60 gloss units at 60 degrees; (v) said opaque layer of drypaint comprises a continuous layer of color that has a length and widththat is substantially coterminous with the length and width of thepressure sensitive adhesive; and (vi) said architectural surfacecovering product is free of any additional releasable liner coveringsaid pressure sensitive adhesive.
 19. The architectural surface coveringproduct of claim 18 wherein the sheet of dry color component with theadhesive thereon exhibits an elongation of less than or equal to 25%when measured according to ASTM D882.